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WO2016179132A1 - Système et procédé pour l'élimination de blocage de condensat avec un matériau céramique et des micro-ondes - Google Patents

Système et procédé pour l'élimination de blocage de condensat avec un matériau céramique et des micro-ondes Download PDF

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Publication number
WO2016179132A1
WO2016179132A1 PCT/US2016/030495 US2016030495W WO2016179132A1 WO 2016179132 A1 WO2016179132 A1 WO 2016179132A1 US 2016030495 W US2016030495 W US 2016030495W WO 2016179132 A1 WO2016179132 A1 WO 2016179132A1
Authority
WO
WIPO (PCT)
Prior art keywords
wellbore
ceramic
containing material
temperature
microwave
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2016/030495
Other languages
English (en)
Inventor
Muhammad Ayub
Sameeh I. BATARSEH
Nabeel S. HABIB
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saudi Arabian Oil Co
Aramco Services Co
Original Assignee
Saudi Arabian Oil Co
Aramco Services Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Saudi Arabian Oil Co, Aramco Services Co filed Critical Saudi Arabian Oil Co
Priority to CA2983101A priority Critical patent/CA2983101C/fr
Priority to CN201680026256.7A priority patent/CN107787391B/zh
Priority to EP16724998.6A priority patent/EP3292267A1/fr
Publication of WO2016179132A1 publication Critical patent/WO2016179132A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B36/00—Heating, cooling or insulating arrangements for boreholes or wells, e.g. for use in permafrost zones
    • E21B36/04—Heating, cooling or insulating arrangements for boreholes or wells, e.g. for use in permafrost zones using electrical heaters
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/12—Methods or apparatus for controlling the flow of the obtained fluid to or in wells
    • E21B43/121—Lifting well fluids
    • E21B43/13—Lifting well fluids specially adapted to dewatering of wells of gas producing reservoirs, e.g. methane producing coal beds
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B47/00—Survey of boreholes or wells
    • E21B47/06—Measuring temperature or pressure
    • E21B47/07—Temperature
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/64—Heating using microwaves
    • H05B6/72—Radiators or antennas
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/64—Heating using microwaves
    • H05B6/80—Apparatus for specific applications
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B37/00—Methods or apparatus for cleaning boreholes or wells
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/16—Enhanced recovery methods for obtaining hydrocarbons
    • E21B43/24—Enhanced recovery methods for obtaining hydrocarbons using heat, e.g. steam injection
    • E21B43/2401—Enhanced recovery methods for obtaining hydrocarbons using heat, e.g. steam injection by means of electricity
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2206/00—Aspects relating to heating by electric, magnetic, or electromagnetic fields covered by group H05B6/00
    • H05B2206/04—Heating using microwaves
    • H05B2206/045—Microwave disinfection, sterilization, destruction of waste...

Definitions

  • the present disclosure relates to operations in a wellbore associated with the production of hydrocarbons. More specifically, the disclosure relates to systems and methods for reducing or removing condensate blockage in and around a natural gas wellbore.
  • Free liquids, or "condensates” (oil and water), from the reservoir can also enter a wellbore along with the natural gas being produced.
  • the natural gas stream in transit to the surface can carry these liquids up-hole by viscous drag forces.
  • the velocity of the gas stream is often reduced to less than a "critical velocity” that is required to carry the liquids to the surface.
  • liquid loading at less than the critical velocity, liquids begin to accumulate in the wellbore in a phenomenon called "liquid loading.”
  • Liquid loading in a low-pressure wellbore can inhibit the production of natural gas from the wellbore. For instance, accumulation of liquids increases the backpressure against the flowing bottom hole pressure, which can result in a cessation of production. Additionally, accumulated liquids can interact with an inner lining of production tubing, yielding corrosion and scaling.
  • Well deliquification and liquid-unloading techniques can be employed to remove accumulated liquids from a wellbore and near-wellbore formation.
  • submersible pumping systems can be installed in a wellbore, or techniques such as plunger lifting can be employed, in which a plunger is raised through the tubing of a wellbore to sweep liquids to the surface for removal.
  • plunger lifting can be employed, in which a plunger is raised through the tubing of a wellbore to sweep liquids to the surface for removal.
  • these procedures which attempt to remove liquid that has already accumulated in a wellbore, are associated with relatively great operating costs and often require temporarily shutting down, or cycling the wellbore.
  • a system for deliquifying a wellbore and a near-wellbore formation by reducing the presence of condensed fluid includes a ceramic -containing material disposed within the wellbore and proximate to a reservoir formation, where the reservoir formation comprises hydrocarbon-bearing strata and a microwave producing unit operable to produce microwaves which heat the ceramic- containing material.
  • the microwave producing unit comprises a microwave antenna disposed within the wellbore and proximate the ceramic-containing material.
  • the ceramic- containing material is operable to be heated to a first temperature by absorbing microwaves produced by the microwave producing unit and is operable to heat the reservoir formation proximate the wellbore to a second temperature.
  • the second temperature is operable to evaporate the condensed fluid, such that fluid condensation is mitigated in the vicinity of the wellbore.
  • the microwave antenna is disposed within the wellbore proximate a tubing string.
  • the ceramic -containing material is operable to heat the reservoir formation proximate the wellbore to a third temperature, where the third temperature is greater than a cricondentherm temperature of the reservoir formation.
  • the ceramic-containing material includes a ceramic made from natural clay, where the natural clay comprises at least one compound selected from the group consisting of silica, alumina, magnesium oxide, potassium, iron oxide, calcium oxide, sodium oxide, titanium oxide, and mixtures thereof. Still in other embodiments, the ceramic-containing material comprises between 50% and 70% by volume of the ceramic.
  • the ceramic-containing material comprises a ceramic made from natural clay, where the natural clay comprises by weight 67.5% silica, 22.5% alumina, 3.10% magnesium oxide, 0.85% potassium, 0.70% iron oxide, 0.35% calcium oxide, 0.30% sodium oxide, and 0.30% titanium oxide. Still in other embodiments, the ceramic -containing material can be heated to between 800 °C and 1000 °C. In some embodiments, the ceramic- containing material further comprises gravel particulate. In some embodiments, the wellbore comprises an open-hole liner. Still in other embodiments, the wellbore is under-reamed. In certain embodiments, the wellbore further comprises cement and a casing with perforations. Still in other embodiments, the condensed fluid is at least one material selected from the group consisting of water, wax, asphaltenes, gas-hydrates, and mixtures thereof.
  • the method includes the steps of activating the microwave producing unit, heating the ceramic-containing material to the first temperature, the first temperature being selected such that the first temperature is operable to sufficiently heat the reservoir formation proximate the wellbore to the second temperature, and monitoring the wellbore for the presence of liquids in a production fluid.
  • the method further includes the step of adjusting an operating parameter of the microwave producing unit to create sufficient heat in the ceramic-containing material to be transferred to the reservoir formation proximate the wellbore, such that fluid condensation is mitigated in the vicinity of the wellbore.
  • the operating parameter of the microwave is at least one operating parameter selected from the group consisting of a positioning of the microwave producing unit proximate the wellbore, an operating power level of the microwave producing unit, a number of microwave producing points on the microwave antenna, and a period of application of microwaves to the ceramic-containing material.
  • a method of reducing the presence of condensed fluid in a wellbore and a near-wellbore formation includes the steps of disposing a ceramic - containing material within the wellbore and proximate to a reservoir formation, where the reservoir formation comprises hydrocarbon-bearing strata and providing a microwave producing unit operable to heat the ceramic-containing material, where the microwave producing unit comprises a microwave antenna disposed within the wellbore and proximate the ceramic-containing material.
  • the method further includes the steps of activating the microwave producing unit to heat the ceramic-containing material, where the ceramic- containing material is operable to absorb microwaves produced by the microwave producing unit and heating the ceramic-containing material to a first temperature, the first temperature operable to heat the reservoir formation proximate the wellbore to a second temperature, where the second temperature is sufficient to evaporate the condensed fluid, such that fluid condensation is mitigated in the vicinity of the wellbore.
  • the microwave antenna is disposed within the wellbore proximate a tubing string.
  • the method includes the step of heating the reservoir formation proximate the wellbore to a third temperature, where the third temperature is greater than a cricondentherm temperature of the reservoir formation.
  • the method further includes the step of determining a cricondentherm temperature of the reservoir formation before activating the microwave producing unit.
  • the ceramic-containing material comprises a ceramic made from natural clay, where the natural clay includes at least one compound selected from the group consisting of silica, alumina, magnesium oxide, potassium, iron oxide, calcium oxide, sodium oxide, titanium oxide, and mixtures thereof.
  • the ceramic-containing material comprises between 50% and 70% by volume of the ceramic. Still in some other embodiments, the ceramic-containing material comprises a ceramic made from natural clay, where the natural clay comprises by weight 67.5% silica, 22.5% alumina, 3.10% magnesium oxide, 0.85% potassium, 0.70% iron oxide, 0.35% calcium oxide, 0.30% sodium oxide, and 0.30% titanium oxide. In certain embodiments, the ceramic -containing material can be heated to between 800 °C and 1000 °C. In some embodiments, the step of disposing a ceramic-containing material within the wellbore further comprises mixing the ceramic-containing material with gravel particulate.
  • the step of disposing a ceramic-containing material within the wellbore further comprises disposing the ceramic-containing material within an open-hole liner.
  • the condensed fluid is at least one material selected from the group consisting of water, wax, asphaltenes, gas- hydrates, and mixtures thereof.
  • the method comprises the steps of forming the wellbore in the hydrocarbon-bearing formation, the wellbore comprising a wellbore wall, the wellbore wall defining an interface between the wellbore and the hydrocarbon-bearing formation and positioning a liner into the wellbore such that an annular void is formed between an exterior-directed surface of the liner and an interior- directed surface of the wellbore wall.
  • the method further includes the steps of introducing a ceramic-containing material into the annular void and proximate to the hydrocarbon-bearing formation and securing the liner such that the ceramic-containing material is maintained in the annular void at a location to be treated with microwave heating.
  • the method further includes the step of introducing into the wellbore a microwave producing unit operable to produce microwaves which heat the ceramic-containing material, where the microwave producing unit comprises a microwave antenna, disposed within the wellbore and proximate the ceramic-containing material, where the ceramic-containing material is operable to be heated to a first temperature by absorbing microwaves produced by the microwave producing unit and is operable to heat the reservoir formation proximate the wellbore to a second temperature, and where the second temperature is operable to evaporate condensed fluid, such that fluid condensation is reduced in the vicinity of the wellbore.
  • a microwave producing unit comprises a microwave antenna, disposed within the wellbore and proximate the ceramic-containing material, where the ceramic-containing material is operable to be heated to a first temperature by absorbing microwaves produced by the microwave producing unit and is operable to heat the reservoir formation proximate the wellbore to a second temperature, and where the second temperature is operable to evaporate condensed fluid, such that fluid condensation is reduced in the vicinity of the wellbore
  • the step of forming the wellbore further comprises the step of extending a radial circumference of a first portion of the wellbore to a radially-larger, under- reamed circumference relative to a second portion of the wellbore, where a radial circumference of the second portion of the wellbore is less than the radial circumference of the radially-larger, under-reamed circumference.
  • the method further comprises the step of disposing cement within the annular void. Still in other embodiments, the method further includes the step of disposing a casing within the annular void.
  • the method further comprises the step of perforating the cement and the casing, such that a hydrocarbon fluid flow is permitted through the perforations radially inward from the wellbore wall.
  • the step of introducing into the wellbore the microwave producing unit further comprises disposing the microwave producing unit within the wellbore proximate a tubing string.
  • the ceramic-containing material is operable to heat the reservoir formation proximate the wellbore to a third temperature, where the third temperature is greater than a cricondentherm temperature of the reservoir formation.
  • the ceramic-containing material comprises a ceramic made from natural clay, where the natural clay comprises at least one compound selected from the group consisting of silica, alumina, magnesium oxide, potassium, iron oxide, calcium oxide, sodium oxide, titanium oxide, and mixtures thereof. In some embodiments, the ceramic-containing material comprises between 50% and 70% by volume of the ceramic. In other embodiments, the ceramic-containing material comprises a ceramic made from natural clay, where the natural clay comprises by weight 67.5% silica, 22.5% alumina, 3.10% magnesium oxide, 0.85% potassium, 0.70% iron oxide, 0.35% calcium oxide, 0.30% sodium oxide, and 0.30% titanium oxide.
  • the ceramic-containing material can be heated to between 800 °C and 1000 °C.
  • the ceramic-containing material further comprises gravel particulate.
  • the step of positioning a liner further comprises the step of positioning an open-hole liner within the wellbore.
  • the condensed fluid is at least one material selected from the group consisting of water, wax, asphaltenes, gas -hydrates, and mixtures thereof.
  • FIG. 1 is a schematic view of an embodiment of a microwave deliquification system in accordance with the present disclosure for reducing or removing condensate blockage in and around a natural gas wellbore, including a microwave antenna and ceramic-containing material.
  • FIG. 2 is a schematic view of an embodiment of a microwave deliquification system in accordance with the present disclosure utilized with an under-reamed wellbore.
  • FIG. 3 is a schematic view of an embodiment of a microwave deliquification system in accordance with the present disclosure utilized with perforations and an open-hole liner.
  • FIG. 4A is a pictorial representation of one embodiment of ceramic material for use in embodiments of the present disclosure.
  • FIG. 4B is a pictorial representation of one embodiment of ceramic material for use in embodiments of the present disclosure while being provided with microwave energy.
  • FIG. 4C is a pictorial representation of one embodiment of ceramic material for use in embodiments of the present disclosure after being provided with microwave energy.
  • FIG. 5 is a pressure-temperature phase diagram of a reservoir fluid in one embodiment.
  • FIG. 6 is a graph showing a decrease in relative permeability of a gas at increased condensate saturation in one embodiment.
  • FIG. 7 is a graph showing potential performance increases for a well in one embodiment of the present disclosure.
  • a hydrocarbon-bearing reservoir 12 includes a wellbore 14, which itself includes tubing 16, packer 18, a casing 20, and cement 22.
  • the wellbore 14 proceeds through a cap rock 24 into the hydrocarbon-bearing reservoir 12.
  • the systems and methods of the present disclosure are used to reduce or remove condensates near the wellbore in a hydrocarbon-bearing reservoir by heating, the systems and methods can be used in other reservoir types for other applications.
  • the systems and methods can be used for heating in oil reservoirs for heavy-oil and bitumen recovery with a single well process, also known as "huff-n-puff ' (using steam injection), and for enhanced oil recovery displacement processes using multiple wells.
  • wellbore 14 further includes an open-hole liner 26, which proceeds downwardly into the wellbore 14 from the cap rock 24.
  • the open-hole liner 26 is disposed within the wellbore 14 and retains a ceramic-containing material 28 between the open-hole liner 26 and the hydrocarbon-bearing reservoir 12.
  • the open-hole liner 26 has an interior-directed surface 25 and an exterior-directed surface 27, which is in communication with the ceramic-containing material 28.
  • the casing 20 and the cement 22 do not proceed below the cap rock 24. However, in other embodiments, the casing and the cement can proceed downwardly below the cap rock, and optionally have perforations, as shown in FIG. 3 and described as follows.
  • the radially-outward limit of the wellbore 14 is defined by a wellbore wall 29.
  • the wellbore wall 29 is the contact or physical interface between the hydrocarbon-bearing reservoir 12 and the ceramic-containing material 28.
  • An annular void 31 is formed between the exterior-directed surface 27 of the liner 26 and the wellbore wall 29. The annular void 31 secures the ceramic-containing material 28 between the liner 26 and the wellbore wall 29 in such a way that the ceramic-containing material 28 can be heated by a microwave producing unit with a microwave antenna 30.
  • the microwave producing unit with the microwave antenna 30 is disposed interior to the open-hole liner 26.
  • Microwave antenna 30 includes substantially equally spaced microwave-producing (emitting) points 32, and as shown microwave-producing (emitting) points 32 direct microwaves 34 radially outwardly or exteriorly and toward the ceramic-containing material 28, within annular void 31.
  • non-open hole liners may be used within the wellbore, or at certain positions within wellbore.
  • the open-hole liner 26 allows for passage of the microwaves 34 from microwave antenna 30 into ceramic-containing material 28 within the annular void 31.
  • the size, positioning, material composition, and number of holes in open- hole liner 26 can be adjusted for optimum passage of microwaves 34 into ceramic-containing material 28. Any suitable liner material, shape, continuity and thickness can be used which allows for passage of microwaves 34 into ceramic-containing material 28.
  • the microwave antenna 30 can be attached to the tubing 16, or can be disposed within the wellbore 14 separately from the tubing 16.
  • the microwave antenna 30 is coupled to the tubing 16 by a coupling device 17.
  • the coupling device is a hanger used by itself or in combination with one or more of screws, bolts, brackets, adhesives, springs, actuators, cords, and other suitable coupling means known in the art. More or fewer coupling devices could be used.
  • microwave antenna 30 can be controlled by a user from the surface away from the wellbore 14, and the microwave antenna 30 can be powered by any means known in the art including, but not limited to, any one of or any combination of solar, combustion, and wind power.
  • downhole thermostats 19 are coupled to the microwave antenna 30 to detect the temperature of the wellbore 14 and areas proximate to the wellbore 14, such as a heated region 36.
  • the microwave antenna 30 maintains the temperature of the wellbore 14 and proximate area, such as the heated region 36, greater than a cricondentherm temperature of the hydrocarbon-bearing reservoir 12.
  • Cricondentherm temperature is described further as follows with regard to FIG. 5. By maintaining the temperature at temperatures greater than the cricondentherm temperature, this allows gas production as a single-phase by keeping the operating conditions of temperature and pressure out of a two-phase region, or a region where the gas contains both liquid fluid and gas vapor.
  • the downhole thermostats 19 detect the temperature proximate the wellbore 14, and if the temperature drops to less than a known, pre-set cricondentherm temperature, the microwave antenna 30 is adjusted to increase the temperature.
  • the downhole thermostats 19 can wirelessly signal surface controls (not shown) to either automatically increase the power (WATTAGE) to the microwave antenna 30, or the downhole thermostats 19 can wirelessly signal surface controls to prompt a user to increase the power to the microwave antenna 30.
  • any downhole temperature detection means can be connected by either or both of wired and wireless means to surface controls. If the temperature detected downhole is less than or decreasing to approach a known, pre-set cricondentherm temperature, the surface controls can be programmed to automatically increase the intensity of the microwave antenna 30, or the surface controls can be programmed to prompt a user that the temperature downhole is approaching or has dropped to less than a cricondentherm temperature and that the power to the microwave antenna 30 should be increased. Other operating parameters of the microwave antenna 30 could also be adjusted, such as the length of the active run time.
  • the microwave antenna would run only to raise and maintain a pre-determined temperature level that is reasonably greater than a known cricondentherm temperature of a reservoir, near the wellbore.
  • the surface controls can be set to deactivate the microwave antenna 30 once the downhole thermostats 19 detect that the desired temperature level is reached.
  • the surface controls can be programmed such that the system will re-activate once the downhole temperature approaches the cricondentherm temperature through cooling.
  • the sequence of activating and deactivating the microwave antenna 30 can continue as required to keep the temperature of the wellbore 14 and proximate areas such as the heated region 36 at temperatures greater than the cricondentherm temperature.
  • the microwave antenna 30 is installed below the coupling device 17.
  • the antenna can be protected from harsh wellbore environments, which may exhibit extremely high temperature, pressure, and erosion caused by possible sand production.
  • the microwave producing points 32 along the microwave antenna 30 heat the ceramic-containing material 28, which in turn produces the heated region 36 within the hydrocarbon-bearing reservoir 12.
  • the heated region 36 is disposed within the hydrocarbon- bearing reservoir 12 along the wellbore wall 29, opposite of the open-hole liner 26.
  • the extent of the heated region 36 into the hydrocarbon-bearing reservoir 12 will depend upon many factors, including, but not limited to, characteristics of the microwave antenna 30, characteristics of the hydrocarbon-bearing reservoir 12, and operating conditions of the microwave deliquification system 10, including the type and amount of the ceramic- containing material 28.
  • the heated region 36 can reduce the formation of and remove the presence of a condensate in wellbore 14, heated region 36, dropout region 38, and areas of hydrocarbon-bearing reservoir 12 radially outward from dropout region 38.
  • condensate dropout region 38 condensate forms as described with reference to the phase diagram of FIG. 5.
  • fluid in vapor form will condense at lesser temperatures to a condensed fluid.
  • Condensate dropout, or condensed fluids, in the condensate dropout region 38 significantly hinder gas production rates from hydrocarbon-bearing reservoirs. By reducing the formation of and removing the presence of the condensate dropout region 38, upward gas flow through wellbore 14 is increased. By increasing the temperature in the heated region 36, condensed fluids in the condensate dropout region 38 are re-evaporated into and maintained in the vapor phase.
  • the microwave antenna 30 is activated by a user to produce the microwaves 34 which are emitted radially outwardly to heat ceramic- containing material 28.
  • the ceramic -containing material 28 is heated to a first temperature, which in turn heats the heated region 36 to a second temperature.
  • the second temperature is at or greater than the temperature required to evaporate condensed fluids in the condensate dropout region 38.
  • FIG. 1 can be used for the complete or partial reduction and removal of gas-condensate accumulated around gas wells
  • the technology of the present disclosure can also be used in the following circumstances: complete or partial reduction and removal of water accumulated around oil and gas wells; complete or partial reduction and removal of wax accumulated around oil wells; complete or partial reduction and removal of asphaltenes accumulated around oil wells; complete or partial reduction and removal of gas- hydrates accumulated around gas wells; clay stabilization around oil and gas wells to minimize the formation damage and to improve the flow conditions; improving oil and gas well performance by minimizing formation damage caused during drilling processes; improving heavy-oil and bitumen recovery using single well "huff-n-puff ' (also known as steam injection) processes; increasing near-wellbore formation pressures; and using multiple wells for enhanced oil recovery displacement processes.
  • huff-n-puff ' also known as steam injection
  • the ceramic-containing material 28 can be substantially pure or unmixed ceramic material, and in other embodiments the ceramic-containing material can be a ceramic and gravel mixture.
  • the ceramic material itself can be any ceramic material capable of being heated by microwaves to a suitable temperature in a suitable amount of time for reducing or removing condensate in a near-wellbore formation by heating.
  • one such ceramic material is produced by the Bezen Institute, Inc.
  • natural clays used to manufacture suitable ceramics include one or more of the following compounds in any combination: silica; alumina; magnesium oxide; potassium; iron oxide; calcium oxide; sodium oxide; and titanium oxide.
  • the ceramics can be reusable, reshapeable, and have a long active life span, such as, for example, about 10 years.
  • gravel packs are used to control sand production along the gas flow from hydrocarbon-bearing reservoirs towards wellbores.
  • Rock mixes such as gravel have a large heat absorbing capacity, and these rocks can absorb heat and stay at a greater temperature for a longer duration than other materials, such as ceramic material by itself. Ceramic materials of the present embodiments, however, have a rapid heating ability when exposed to microwaves.
  • Mixing ceramic with an appropriate rock mix, such as gravel serves at least two purposes: (1) the total ceramic volume in the mixture is reduced for economic reasons as rock mixtures such as gravel are more economical, and (2) once the ceramic material is quickly heated by being exposed to microwaves, the rock mix such as gravel can absorb a large amount of heat and sustain a high temperature for a long duration to continuously transfer heat to adjacent reservoir rocks.
  • a suitable mixture of ceramic and gravel material can provide better and sustained levels of heat transfer from the mixture to an adjacent region, such as the heated region 36 and dropout region 38 of FIG. 1.
  • the volume percentage of the ceramic material could be about 40%, 50%, 60%, 70%, or 80% of the total ceramic-gravel mixture volume.
  • natural clays used to manufacture suitable ceramics include about 67.5% silica, 22.5% alumina, 3.10% magnesium oxide, 0.85% potassium, 0.70% iron oxide, 0.35% calcium oxide, 0.30% sodium oxide, and 0.30% titanium oxide.
  • such ceramics can be reusable, reshapeable, and have a long active life span, such as about 10 years.
  • any suitable and advantageous particle size for the ceramic material and gravel can be used.
  • any suitable and advantageous ratio of ceramic material to gravel, or similar rock mixes can be used.
  • a suitable ratio of ceramic to gravel would provide for quick heating of the ceramic material to a high temperature followed by absorption of a large amount of heat by the gravel mixture and sustained heating of the wellbore and near-wellbore formation provided by the large amount of heat absorbed by the gravel mixture.
  • ceramic-containing material can be heated by microwaves into the temperature range of about 800 °C to about 1000 °C in about three minutes (see FIGS. 4A-C).
  • the ceramic-containing material 28 would be placed proximate to the "pay zone" of hydrocarbon-bearing reservoir 12, or the area from where hydrocarbons are being produced and hence condensate accumulation or blockage may occur (gas flow shown).
  • the ceramics used in the embodiments of the present disclosure do not quickly deteriorate, and they do not leach harmful substances when used. Therefore, these ceramics could be employed safely and for long periods of time in a wellbore formation such as, for example, about 10 years.
  • the system of FIG. 1 surprisingly and unexpectedly provides a unique means to reduce the formation of or remove fluid condensates by heating.
  • Conventional microwave heating without ceramic-containing material, does not work effectively to evaporate gas- condensate in wellbores, because there is insufficient water in the vicinity of the wellbores to effectively absorb microwave radiation and be heated.
  • water is heated by microwaves, for example in conventional kitchen microwaves; however, in the system of FIG. 1, ceramic-containing material 28 can be quickly and efficiently heated by microwaves without the presence of water.
  • the dropped-out or condensed liquid in a near-wellbore formation mainly consists of crude oil, which also condenses within the wellbore. This eventually reduces the production rate of gas to less than the economic limits.
  • the microwaves 34 interact with the ceramic-containing material 28, a tremendous amount of heat is created that can evaporate both gas-condensate and water; hence improving the near-wellbore gas flow conditions.
  • FIG. 2 a schematic view of a microwave deliquification system 50 with an under-reamed wellbore 52 is shown. Components shown are similar to those shown in FIG. 1 and described previously. However, in the under-reamed wellbore 52, the ceramic- containing material 54 extends radially further into the hydrocarbon-bearing reservoir 56 than the ceramic-containing material 28 extends into the hydrocarbon-bearing reservoir 12 in FIG. 1. In some embodiments, an under-reamed, open-hole liner completion is preferable, because the radial thickness of the ceramic-containing material would be larger compared to other completion designs (see FIG. 1). Such a design can provide more efficient heating, and allow for longer-life of the ceramic-containing material.
  • the radially-outward limit of the under-reamed wellbore 52 is defined by a wellbore wall 53.
  • the wellbore wall 53 is the contact or physical interface between the hydrocarbon-bearing reservoir 56 and the ceramic-containing material 54.
  • An annular void 55 is formed between an exterior-directed surface 57 of an open-hole liner 51 and the wellbore wall 53.
  • the annular void 55 secures the ceramic-containing material 54 between the liner 51 and the wellbore wall 53 in such a way that the ceramic-containing material 54 can be heated by a microwave producing unit with a microwave antenna 59.
  • the annular void 55 in FIG. 2 is radially larger than the annular void 31 in FIG. 1, and this can provide enhanced heating of the hydrocarbon-bearing reservoir 56.
  • FIG. 3 a schematic view of a microwave deliquification system 60 within a wellbore 62 is shown. Components shown are similar to those shown in FIGS. 1 and 2 described previously. However, in the embodiment of FIG. 3, cement 64 and a casing 66 extend below a cap rock 68 downwardly into the wellbore 62. Perforations 70 are shown to extend from a hydrocarbon-bearing reservoir 72 through the cement 64 and casing 66 into ceramic-containing material 74. The wellbore 62 is pictured with an open-hole liner 76. The perforations 70 will allow hydrocarbon flow from the hydrocarbon-bearing reservoir 72 to the wellbore 62.
  • the perforations 70 can allow for more efficient heat transfer from the ceramic-containing material 74 to the surrounding hydrocarbon-bearing reservoir 72. Any number, size, shape, and arrangement of the perforations 70 is envisioned for efficient hydrocarbon flow and heat transfer to occur between ceramic -containing material 74 and hydrocarbon-bearing reservoir 72.
  • a wellbore wall 63 is the contact or physical interface between the hydrocarbon-bearing reservoir 72 and the cement 64.
  • An annular void 65 is formed between an exterior-directed surface 67 of the open-hole liner 76 and an interior- directed surface 69 of the casing 66.
  • the annular void 65 secures the ceramic-containing material 74 between the liner 76 and the casing 66 in such a way that the ceramic -containing material 74 can be heated by a microwave producing unit with a microwave antenna 78.
  • the annular void 65 in FIG. 3 is radially smaller than the annular void 55 in FIG. 2.
  • perforations may extend into an annular void containing ceramic-containing material, and some portion of the ceramic-containing material may extend radially outwardly and into the perforations, a casing, and cement.
  • the perforations 70 extend from the casing 66 through the cement 64, and into the hydrocarbon-bearing reservoir 72; however, the perforations do not have a substantial amount of ceramic-containing material 74 within the perforations 70.
  • a substantial amount of ceramic-containing material may reside in perforations extending into hydrocarbon-bearing formations.
  • a method for creating and using one or more of such systems can include the following steps. First, a candidate hydrocarbon well, optionally containing one or both of gas and oil, would be selected, optionally with one or more pre-existing condensate issues, and optionally at risk of future condensate issues. In one embodiment, a well with open-hole completion would be selected, because in open-hole completion there will be no casing disposed between the microwave generator(s) and the ceramic-containing material. Therefore, the ceramic-containing material, optionally mixed with gravel, will be better exposed to microwaves for effective heating.
  • one or more condensate samples would be collected from the selected well, and complete lab studies would be performed to determine fluid composition and pressure- volume-temperature (PVT) properties of the fluid in the well.
  • PVT pressure- volume-temperature
  • a phase diagram such as that shown in FIG. 5 and described as follows, could be developed to determine the necessary increase in temperature for the well to avoid condensates (for example, at and greater than the dew-point line and cricondentherm temperature). Thereby, the required amount of heat/energy from microwaves to increase the near-wellbore formation to this temperature could also be calculated.
  • the well could be completed with any of the typical sand control processes shown in FIGS. 1-3.
  • an under-reamed, open-hole completion such as that shown in FIG. 2, can be preferable, because in this design the radial thickness of a ceramic-gravel mix would be larger compared to the other completion designs (see FIGS. 1-3).
  • Such a design would lead to better and long-life heating for certain wellbores.
  • Completing the well can include any steps such as packer placement, forming perforations, and setting the liner before any hydrocarbons are produced from the well.
  • one or more microwave systems could be installed, for example as shown in FIGS. 1-3.
  • the microwave supply could be activated from a surface control system capable of accepting user input.
  • the system would then remain activated during gas production to allow the near-wellbore formation and fluids to heat up to a temperature greater than the cricondentherm temperature level (see FIG. 5).
  • the microwave antenna can run continuously to maintain the near-wellbore temperature greater than a cricondentherm temperature, or it can be run intermittently to maintain the near- wellbore temperature greater than a cricondentherm temperature.
  • the microwave antenna can be activated and deactivated by a user, and it can be controlled by a control loop interacting with one or more temperature and pressure sensors actively tracking the temperature and pressure in the near-wellbore formation.
  • Heating should be continued for a sufficient time (to be determined with the help of commercially available thermal simulators such as Eclipse or CMG) to make sure most of the near-wellbore accumulated liquids are evaporated.
  • the on/off duration of heating cycles, to maintain temperature greater than the cricondentherm level, can be controlled by at least one downhole thermostat installed with the downhole antenna. Heating of the near-wellbore formation can be performed while the well is flowing, or while production from the well is suspended.
  • the condensate composition and PVT properties of the well can change. This can shift the phase-diagram of the near-wellbore formation, such as that shown in FIG. 5, further to the right.
  • the thermostat should be readjusted periodically to keep the downhole operating temperature greater than the cricondentherm level.
  • FIG. 4A a pictorial representation of one embodiment of ceramic material for use in the systems and methods of the present disclosure is shown.
  • FIG. 4A shows the raw form of the ceramic material at ambient conditions.
  • Ceramic material of any suitable mesh-size can be used, and as noted previously, can be used with or without mixing with gravel.
  • One or more advantageous mixing ratios of ceramic material to gravel, or a similar rock mixture can be determined based on reservoir conditions and the severity and type of accumulated condensates and liquids.
  • Various ratios of ceramic material to gravel, or a similar rock mixture can provide advantageous heat transfer characteristics for heat transfer to the near-wellbore formation.
  • FIGS. 4B and 4C pictorial representations are shown of one embodiment of ceramic material being provided with microwave energy. Heated portions 80 are shown to have absorbed microwave energy and are heated to a high temperature. Experiments have shown that temperatures in the range of about 800 °C to about 1000 °C can be achieved in about 3 minutes with a low power microwave, such as a kitchen-type microwave oven. Such experiments show that ceramic -containing materials used in combination with one or more industrial microwave antennas can provide low-cost and efficient systems and methods for heating near-wellbore formations to reduce or remove condensates.
  • Ceramic materials of the present application suggest using a ceramic material having a large thermal conductivity as compared to surrounding wellbore rocks and fluids. Such ceramic material is to overcome a heat penetration limitation commonly encountered in cases where microwave heaters are used to reduce heavy-oil viscosity.
  • ceramic materials work as heat-carrier or heat-transfer materials and do not generate additional heat.
  • the source of heat generation is the microwave heater only. The ceramic carries the heat away from the well to certain limits; and, as steam and vapor cools down, its effectiveness or efficiency also declines with time and distance away from the wellbore.
  • FIGS. 4A-4C show the additional heat generation process.
  • a regular kitchen type microwave can generate temperatures around 200 °C; whereas, when ceramic material of the present application is placed in the same oven, the material's temperature reached around 1000 °C within about 3 minutes.
  • Prior art references do not suggest this ability in ceramic materials applied in oil and gas technologies. Without being bound by any theory or explanation, it is believed that certain minerals in the ceramic materials used in the embodiments of the present disclosure have large surface areas and have large microwave attenuation capacity that causes the rapid heating of the ceramic material in the absence of water. The ceramic -gravel mixtures of the present disclosure likely would be so hot that during operational scenarios water and oil would not be absorbed onto the ceramic; instead, any fluid proximate the ceramic material would be rapidly evaporated.
  • vapor or steam is generated downhole from injected water with the help of microwaves or a radio frequency (“RF") heater, and the steam is injected into a heavy-oil (high viscosity oil) reservoir to reduce viscosity of the oil (described as fluidization) so that it can flow towards the wellbore.
  • RF radio frequency
  • Injected vapor or steam once it enters into the reservoir, reduces the viscosity of heavy-oil or Bitumen, and then it is cooled or condensed down to become just hot-water.
  • the "gas-condensate" described in the present application has no relation at all with that described in certain prior art steam generation applications.
  • Natural gas condensation occurs in most gas wells, and is usually a near-wellbore phenomenon if the gas is produced at less than a certain pressure limit (called dewpoint pressure) while the average reservoir pressure away from the wellbore is larger than the dewpoint pressure levels. Because of lesser near wellbore pressures and temperatures, the heavier components of a typical natural gas get condensed, accumulate around wells, and block the flow paths of gas.
  • dewpoint pressure a certain pressure limit
  • the systems and methods of the present application enable the creation of high enough temperatures downhole near a wellbore to re-evaporate heavy components of natural gas to bring them to the surface as a gas, rather than enabling merely the creation of steam downhole to fluidize heavy oil components.
  • ceramic materials are used as insulators, and are used to insulate against heat or microwaves.
  • the ceramic materials do not act as insulators against heat or microwaves.
  • any ceramic material which is non-conductive to heat and microwaves, and cannot generate additional heat has no relevance with the ceramic material used in the present application.
  • Pressure-temperature phase diagrams can, in some embodiments, be used to determine the heating and temperature increase necessary to be produced by the systems of FIGS. 1-3.
  • a cricondentherm temperature 90 is the maximum temperature greater than which the condensation process, or the formation of a liquid would not occur at any given reservoir pressure. In other words, at reservoir temperatures greater than point G, the hydrocarbon system will remain as a single-phase dry gas regardless of the pressure decline near the wellbore.
  • a critical point 92 is the point at which the hydrocarbons are in a state where all intensive properties of the gas phase and liquid phase are equal. In other words, the gas and liquid phases are not easily distinguishable.
  • the corresponding pressure is the critical pressure (P c ) and the corresponding temperature is the critical temperature (T c ).
  • bubble point line 94 is the line representing temperature and pressure conditions separating the single-phase oil region (liquid oil) from the two-phase region (mixed liquid and gas).
  • Dew-point line 96 is the line representing temperature and pressure conditions separating the single-phase gas region (dry gas) and the retrograde gas- condensate region (vapor gas) from the two-phase region (mixed liquid and gas).
  • the fluid can behave as single-phase oil, single-phase gas, retrograde gas-condensate, or two-phase fluid.
  • initial reservoir fluid conditions can exist at greater than the cricondentherm temperature 90; for example at Point F in FIG. 5.
  • cricondentherm temperature 90 for example at Point F in FIG. 5.
  • a near-wellbore cooling effect can dictate the flow path from point F to point G and further down into two-phase region at point H. This would result in the same undesirable scenario described previously; that is, because of the near- wellbore liquid accumulation, a significant loss of relative permeability to gas can occur which can lead to early well-abandonment.
  • one advantage of using a thermal approach to keep the bottomhole wellbore conditions greater than the dew-point line 96 is that it will not only re- vaporize the condensed liquids, but also re-pressurize the bottomhole pressure.
  • FIG. 1 a pressure profile before heating 40 is increased to a greater pressure profile after heating 42.
  • a cricondentherm temperature is determined for one or more reservoir fluids under near- wellbore conditions, such that the temperature of the near- wellbore environment can be increased to maintain the fluid in a single phase gas region.
  • FIG. 6 a graph showing a decrease in relative permeability of a gas at increased condensate saturation in one embodiment is shown. As shown, saturation buildup around the wellbore can significantly reduce the gas permeability.
  • FIG. 7 a graph showing potential performance increase for a well in an embodiment of the present disclosure is shown.
  • IPR Inflow Performance Relationship
  • VFP Vertical Flow Performance
  • the IPR is a relationship between the flowing bottomhole pressure (PWF) and the flow rate (Q), which represents potential output a reservoir can deliver (see Equation 1 as follows).
  • PWF flowing bottomhole pressure
  • Q flow rate
  • the VFP relates the flowing bottomhole pressure to the surface production rate, which represents potential output a well can deliver.
  • Well performance is usually obtained by conducting various deliverability tests to draw an IPR curve and then coupled with a VFP curve which is mainly based on surface piping, tubing, and the separator conditions.
  • Well performance is also known as Productivity Index (PI).
  • PI Productivity Index
  • Equation 1 fi (gas viscosity) & Z (gas compressibility) are evaluated at average reservoir pressure shown by Equation 2, D _ P R + P WF
  • FIG. 7 shows a combined layout where the intersection of the IPR with the VFP yields the well deliverability, an expression of what a well will actually produce for a given operating condition.
  • Original IPR shows existing IPR and VFP before the treatment with the systems and methods of the present disclosure.
  • Point A represents a current production rate.
  • Improved IPR shows a post-treatment scenario, where, because of anticipated improved near- wellbore conditions brought about by the systems and methods of the present disclosure, the IPR curve is favorably shifted towards the right side of the graph in FIG. 7. Without changing the tubing and other surface conditions (or VFP), the flow rate is significantly improved as shown at Point B. This production rate can further be increased significantly to Point C if the existing tubing is replaced with a larger inside diameter tubing and adjusting the surface conditions accordingly.
  • Embodiments of the present disclosure are well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others that are inherent. While embodiments of the disclosure have been given for purposes of description, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present disclosure and the scope of the appended claims.
  • Optional or optionally means that the subsequently described event or circumstances can or may not occur.
  • the description includes instances where the event or circumstance occurs and instances where it does not occur.
  • Ranges can be expressed throughout the disclosure as from about one particular value to about another particular value. When such a range is expressed, it is to be understood that another embodiment is from the one particular value to the other particular value, along with all combinations within said range.
  • first and second are arbitrarily assigned and are merely intended to differentiate between two or more components of an apparatus. It is to be understood that the words “first” and “second” serve no other purpose and are not part of the name or description of the component, nor do they necessarily define a relative location or position of the component. Furthermore, it is to be understood that that the mere use of the term “first” and “second” does not require that there be any “third” component, although that possibility is contemplated under the scope of the present disclosure.

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Abstract

L'invention porte sur des systèmes et des procédés pour la réduction ou l'élimination d'un blocage de condensat dans un puits de forage de gaz naturel et une formation proche du puits de forage. Selon l'invention, des micro-ondes sont utilisées pour chauffer un matériau contenant de la céramique à l'intérieur d'une formation proche du puits de forage. De la chaleur est transférée du matériau contenant de la céramique à la formation proche du puits de forage. Tous réservoirs de condensat de gaz dans la formation proche du puits de forage sont chauffés et des liquides condensés accumulés autour du puits de forage sont réévaporés.
PCT/US2016/030495 2015-05-05 2016-05-03 Système et procédé pour l'élimination de blocage de condensat avec un matériau céramique et des micro-ondes Ceased WO2016179132A1 (fr)

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CN201680026256.7A CN107787391B (zh) 2015-05-05 2016-05-03 使用陶瓷材料和微波去除凝结物阻塞的系统和方法
EP16724998.6A EP3292267A1 (fr) 2015-05-05 2016-05-03 Système et procédé pour l'élimination de blocage de condensat avec un matériau céramique et des micro-ondes

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CA2983101C (fr) 2019-11-19
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CA2983101A1 (fr) 2016-11-10
EP3292267A1 (fr) 2018-03-14
CN107787391B (zh) 2021-07-16

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